Beruflich Dokumente
Kultur Dokumente
(Common Rail)
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Power-train application
Plant Ulsan (#5) KMS BHMC(#2)
Category Area DOM(’09.8) NA(’09.10) GEN(’09.10) Aust.(’09.10) GEN(’10.4) EU(’10.2) China(’10.4)
Spec. DOM NA GEN Aust. EU EL(ix35) China
Engine T/M 2WD 4WD 2WD 4WD 2WD 4WD 2WD 4WD 2WD 4WD 2WD 4WD 2WD 4WD
γ 1.6 GDI 140/17.0 M5CF1-1 ●
(Hwasong) (PS/kg.m) (HMMC) (’10.11~)
M5GF1 ○ ● ● ● ● ● ● ● ●
Θ-II 2.0 MPI 161/19.8 (Ulsan) (’10.4~)
M6GF2
(Ulsan) ● ●
Θ-II 2.4 MPI 174/23.0
(Asan) (PS/kg.m) A6MF1
(HPT) ● ● ● ● ● ● ●
U2-1.7 VGT 115/26.0 M6CF3-1 ●
(Hwasong) (PS/kg.m) (HMMC) (’10.11~)
M6GF2
● ● ● ● ● ● ● ●
R-2.0 VGT (H) 173/38.0 (Hwasong) (~’10.10) (~’10.10)
M6GF2
(Hwasong) ● ●
R-2.0 VGT (L) 136/32.0
(Ulsan) (PS/kg.m) A6LF2 ●
(HPT) (’10.11~)
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R - Engine 3
Specification
1,995
Displacement (cc) Catalytic Converter WCC+DPF
(In-line 4 cylinders)
DC Motor 45 l/h,
Max. Torque (kgf·m/RPM) 38 / 1,800~2,500 Low Pressure Pump
4.5bar13V
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R - Engine 4
Lay out
Piezo Injector
1800bar Oil Separator Electrical VGT
4 Valve DOHC
Plastic
Head Cover
Vacuum Pump
(operated by camshaft)
Water Pump
EGR COOLER
(By-pass type)
Close-Coupled DPF
Balance Shaft Module Serpentine driving belt
with Oil pump
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R - Engine 5
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R - Engine 6
4
2
5
3
1
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21123-2F000
• Main bearing cap : Watch out direction and sequence • Oil jet cap color :
• Main bearing cap bolt tightening torque : 5kgf.m + 120˚ - Standard engine: Colorless CAP
• Deep skirt iron block + separated bearing cap - Low power engine : Orange color CAP
• Oil level sensor (Only Europe) → ECM → Warning on Cluster
Copyright ⓒ 2009 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
R - Engine 7
Coolant Inlet
Element
Coolant outlet
Oil Filter www.oto-hui.com
Cap O-ring
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R - Engine 8
17 18 19 20
Gasket grade
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Grade 1 2 3 4
(A)
(B)
(C)
8 7 6 5
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R - Engine 9
Oil Separator
Yellow Making
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R - Engine 10
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R - Engine 11
Jiggle valve
Main Features – Cooling
EGR cooler
Oil cooler
EGR cooler hose
hose
Oil cooler
return
hose Water
Outlet
pipe
Oil cooler &
Filter module To
Radiator
• EGR valve and Turbocharger is cooled by coolant
• Inlet control (opening temp. : 82℃, fully open 95℃)
Water pump
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R - Engine 12
23
Thermostat
Oil Cooler
PTC Heater
Turbocharger
EGR Cooler
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Radiator
BY-PASS
Cylinder Block
Cylinder Head
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R - Engine 13
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Isolation damper
pulley Connecting rod
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R - Engine 14
Gear Teeth
Oil Strainer Inspection
Plastic Pin
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Oil Pump
• Applied balance shaft module, which is combined with oil pump and oil strainer.
• Installation procedure
- Match engine timing → Install BSM → Match BSM timing → Confirm BSM rotation smoothly
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R - Engine 15
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Timing Mark
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R - Engine 16
Sealant Plug
Sealant
Confirm
different
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R - Engine 17
<Electrical Actuator>
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<Turbocharger>
• Smart type (Operating driver in VGT actuator) is applied <System Diagram>
Intercooler
Electrical VGT
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Electrical ACV (Air Control Valve)
• Control type : DC Motor
• Purpose :
- For reducing dieseling at IG OFF (Valve is closed)
- For controlling intake air for DPF regeneration
Electrical SCV • Size : Φ57 mm
Copyright ⓒ 2009 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
R - Engine 19
EGR Gas
Coupling (Outlet)
EGR Gas
(inlet)
Return Spring Valve shaft
• Purpose : Exhaust gas recirculation for reducing NOx
Valve Disc • Control type : DC Motor (Position sensor is applied)
- It is for controlling EGR valve accurately.
● EGR Cooler (compared with vacuum type)
High Temp.
Exhaust Gas • Applied By-pass valve
- EGR gas does not pass cooler at cold condition (under 60℃)
• Increased efficiency of EGR cooler
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R - Engine 20
Coupling
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R - Engine 21
When assembling,
Don’t miss O-ring
6 3 10 8 5 Inlet port
9 11 4 7 2 1
1,2 : Tightening torque(2.0~2.7kgf.m)
3~11 : Tightening torque(1.9~2.4kgf.m)
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R - Engine 22
• A : Clamp cap,
• B : Torque control cap Before torque After torque After removing the cap
Service procedure
1) Plier out the intake 2) Loosen the clamp
manifold clamp cap. using a flat head
screwdriver.
Copyright ⓒ 2009 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
R - Engine 23
Exhaust Gas
Temperature Sensor
DPF
Euro-4 Euro-5
Differential Pressure
Sensor
Close-Coupled DPF
Copyright ⓒ 2009 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
R - Engine 24
Post injection
Exhaust gas
DOC
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R - Engine 25
www.oto-hui.com
2. DPF white smoke 4. Soot excess
- Abnormal regeneration (DPF melting) - Soot, oil and fuel excess
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R - Engine 26
28
Fuel Sender
• Prevents fuel leak from the tank and discharges gas vapor in the event
Rollover Valve
of a rollover or excessive body roll.
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R - Engine 27
30
Glow Relay
Engine rpm
• When the ignition is turned on, the fuel pump is not activated right away to reduce noise.
• When an RPM signal is received, however, the fuel pump becomes activated.
• Note that cranking the engine after a fuel line repair can damage the high-pressure fuel pump.
※ After repairing the fuel line (pump, rail, injectors, etc. and including disassembly and replacement),
perform the actuation test in scan tool.
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R - Engine 28
PWM Signal
From ECM
VB > 11.5
Duty control
FET Relay
output
VB ≦ 11.5
Duty 100%
Duty control
STEP 1 STEP 2 STEP 3 STEP 4 STEP 5
Glow Plug
Temp.
Ceramic Glow Plug
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R - Engine 29
ECM
Monitoring Vehicle
LIN
SOC conditions
Alternator
FR Terminal
TPS VSS RPM
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R - Engine 30
L Terminal
C Terminal
Send SOC Request
information SOC information
Decel.
Accel.
Accel.
Vehicle Speed
Voltage
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R - Engine 31
Comparison (2.0/2.2)
Items Parts No. ( 2.2L) Parts No. ( 2.0L) Figure Remarks
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R - Engine 32
Comparison (2.0/2.2)
Items Parts No. ( 2.2L) Parts No. ( 2.0L) Figure Remarks
Copyright ⓒ 2009 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
R - Engine 33
6 Floors 4 Floors
- Different capacity
EGR Cooler
EGR cooler
28416-2F000 28416-2F320
Ceramic Metal
Glow Plug
36710-2F000 36710-2F100
DPF WCC
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R - Engine 34
EDC17CP
Start injection
Amplification
Hydraulic
Opened Control valve coupler
Nozzle needle open Piezo-actuator
Nozzle
needle
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Pressure
control valve
Stop injection
• CRI 3.2
Pressure reduction
• Applied IQA (Injector Quantity Adjustment)
Closed Closed
• Operating Voltage / Ampere : Max. 156V / Max. 17A Nozzle needle control valve
• 8 holes
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R - Engine 36
Voltage
Low pressure line
(1~10bar) time
time
Rail pressure
Amplifier pre. Leakage Refilling
10 bar (Ps>Psys) (Ps<Psys)
1 bar
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R - Engine 37
Control valve
Control outlet
Volume Outlet Inlet
By-pass
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By-pass By-pass
Inlet Closed opened
Inlet Inlet
Needle
Rail pressure
Leakage pressure
Control volume pressure
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R - Engine 38
- Injector response : no delay time between the voltage and the stroke
- Control current : only controls injection starting current and ending current.
[Piezo- Injector]
Injector voltage
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R - Engine 39
Tappet body
Cham shaft
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R - Engine 40
① ②
④
www.oto-hui.com ③
② Install the inner part of the SST on the high pressure pump sprocket
④ Tighten the inner part and outer part with bolts and screw out the high
pressure pump.
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R - Engine 41
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R - Engine 42
Plug Bush
Plug
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R - Engine 43
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Before assembling the Push the plug to Confirm installed Install plug bush until
return line, confirm plug vertical direction until condition by moving plug hear click sound
fixing condition and plug make clicker sound
bush is lifted. from injector nipple
Press both knob and lift Lift up plug vertical -Cause : One plug fixing is broken. Because of
up plug bush direction from injector excessive
nipple at lifted plug bush installation without the plug bush fully up.
- Symptom : Fuel leaks from the injector nipple
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R - Engine 44
RPCV
RPS
FPCV
www.oto-hui.com Inter-
MAF
Sensor
BPS ACV IAT
Piezo injector cooler
CMP
SCV
Fuel Temp. EGR
Sensor cooler
Glow Plug EGR Valve
ECT
sensor VGT
CKP EGR by-pass Lambda
Valve Sensor
LP pump EGR Solenoid
Valve DOC
EGTS
DPF
Sensors LP line
APS
Actuators HP line
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R - Engine 45
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R - Engine 47
CMP
CMP
CKP
CKP
CKP
CMP
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• CMP : Hall IC type sensor
• CKP : Hall IC type sensor
- CKP target wheel : magnetic encoder
Magnetic encoder
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R - Engine 48
18°
15°
6°
Encode S N S N S N S N S N S N S N S
CKP
Output
1.5 CA ± α
No 1 cylinder
TDC
CKP
Signal
102˚ 132˚
CMP
Signal
90˚ 64˚ 64˚
90˚
26˚ 26˚
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R - Engine 49
λ 0.65 0.70 0.80 0.90 1.016 1.18 1.43 1.70 2.42 Air
Pumping
Ampere -2.22 -1.82 -1.11 -0.50 0.00 0.33 0.67 0.94 1.38 2.54
(mA)
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R - Engine 50
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R - Engine 51
4.5
EGTS
1
DPS
0 100
Pressure (kpa)
DPS
• Detect the diff pressure between DPF inlet (upstream) and outlet (downstream) for DPF regeneration
• Output voltage: 1V ~ 4.5
EGTS
• Measure the temperature of DPF for regeneration
• Located between DOC and DPF
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R - Engine 52
MAF Sensor
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R - Engine 53
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R - Engine 54
• Sensor 1
- For injection amount and timing
(torque request signal)
• Sensor 2
- Sensor 1 monitoring,
www.oto-hui.com preventing sudden starting
• Failsafe
- 1,250 rpm fix
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